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Lincoln Electric IM870-A manual

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Table of contents for the manual

  • Page 1

    OPERA T ORʼS MANUAL S AE-400 SEVERE DUTY DC ARC WELDING PO WER SOURCE IM870-A MAY, 2008 For use with machines having Code Number: 11199, 11408 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation o[...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

  • Page 3

    ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 .b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical [...]

  • Page 5

    PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrod[...]

  • Page 6

    ix ix Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. P[...]

  • Page 7

    vi T ABLE OF CONTENTS SAE-400 SEVERE DUTY vi Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Installation Precautions . . . . . . . . .[...]

  • Page 8

    A-1 INST ALLA TION SAE-400 SEVERE DUTY A-1 TECHNICAL SPECIFICA TIONS - SAE-400 SEVERE DUTY Make/Model Description Speed (RPM) Displacement Starting Capacities System Perkins 4 cylinder High Idle 1800 269 cu. in 12VDC batteries Fuel: 22.5 gal. 1104C-44 Diesel 68.4 HP @ Low Idle 1100 (4.4 L) (2 ) & Starter 85.1 L Engine 1725 RPM Full Load 1725 Bo[...]

  • Page 9

    A-2 INST ALLA TION SAE-400 SEVERE DUTY A-2 Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and [...]

  • Page 10

    A-3 INST ALLA TION SAE-400 SEVERE DUTY A-3 HIGH AL TITUDE OPERA TION At higher altitudes, output derating may be necessary. As a rule of thumb, derate the welder output 5% for every 500 meters (1640 ft.) above 1000 meters (3280 ft.). Contact a Perkins Service Representative for any engine adjustments that may be required for high alti- tude operati[...]

  • Page 11

    A-4 INST ALLA TION A-4 SAE-400 SEVERE DUTY BA TTER Y CONNECTION WARNING: Use caution as the electrolyte is a strong acid that can burn skin and damage eyes. Remove and discard the insulating caps from the neg- ative battery terminals. Attach and tighten negative battery cable terminals. NOTE: This machine is furnished with wet charged batteries; if[...]

  • Page 12

    A-5 INST ALLA TION SAE-400 SEVERE DUTY A-5 WELDING OUTPUT CABLES With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if neces- sary. Listed in Table A.1 are copper cable sizes recom- mended for the rated current and duty cycle. Lengths stipulated are the di[...]

  • Page 13

    B-1 OPERA TION B-1 WELDING SP ARKS can cause fire or explosion. • Do not weld near flammable material . • Do not weld on containers that have held flammable material. -------------------------------------------------------------- MOVING PARTS can injure. • Keep away from moving parts • Do not operate with doors open or guards off. • Stop [...]

  • Page 14

    B-2 OPERA TION B-2 DESIGN FEA TURES AND ADV ANT AGES FOR STICK WELDING • Excellent DC constant current output for stick weld- ing applications. • Continuous adjustment of both voltage and current for unsurpassed welds on demanding jobs. • Remote control capability standard. FOR AUXILIARY POWER • 3,000 watts of 115/230 VAC, 60 Hz auxiliary p[...]

  • Page 15

    B-3 OPERA TION B-3 ENGINE CONTROLS IGNITION SWITCH When placed in the “ON” position, this switch ener- gizes the fuel solenoid. When placed in the “OFF” position, the flow of fuel to the injection pump is stopped to shut down the engine. “IDLER” SWITCH The idler switch has two positions, “HIGH” and “AUTO”. When in “HIGH” ( )[...]

  • Page 16

    B-4 OPERA TION B-4 WELDER CONTROLS POLARITY SWITCH Turn the Arc Polarity switch to electrode positive or electrode negative as required for each particular application. CONTROL OF WELDING CURRENT Purpose of Controls The continuous “Current Control” is the main current adjuster. The “Job Selector” is both a fine current adjuster and the cont[...]

  • Page 17

    B-5 OPERA TION B-5 SAE-400 SEVERE DUTY ENGINE OPERA TION For added safety always operate the welder with the doors closed. Further, leaving the doors open changes the designed air flow and may cause engine, generator overheating. Do not adjust the high idle engine speed (rpm) above the factory setting specification as this will void warranty. -----[...]

  • Page 18

    B-6 OPERA TION B-6 SAE-400 SEVERE DUTY TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE-400 for vari- ous operating scenarios is shown below: Low Idle - No Load .30 gal./ hr. 1100 RPM (1.12 L./hr.) High Idle - No Load .69 gal./hr. 1800 RPM (2.61 L./hr.) Welding Load 1.79 gal./hr. 400 Amps, 40 Volts (6.76 L./hr.) Welding Load 2.43 ga[...]

  • Page 19

    C-1 ACCESSORIES C-1 OPTIONAL FIELD INST ALLED ACCESSORIES K802-D Power Plug Kit - Kit includes male plugs for 20 Amp receptacle. K2641-1 Trailer - A 4-wheel steerable trailer for in- plant and yard towing (1) with E78-14 load range (B) tubeless tires. Mounts directly to welder base.(Not for use on the highway.) Comes standard with a Duo-Hitch™, a[...]

  • Page 20

    D-1 MAINTENANCE D-1 ELECTRIC SHOCK can kill. ● Do not touch electrically live parts such as output terminals or inter- nal wiring ENGINE EXHAUST can kill. ● Use in open, well ventilated areas or vent exhaust outside MOVING PARTS can injure. ● Do not operate with doors open or guards off ● Stop engine before servicing ● Keep away from movi[...]

  • Page 21

    D-2 MAINTENANCE D-2 BEARING MAINTENANCE This welder is equipped with a double-shielded ball bearing having sufficient grease to last indefinitely under normal ser- vice. Where the welder is used constantly or in excessively dirty locations, it may be necessary to add one-half ounce of grease per year. A pad of grease one inch wide, one inch long an[...]

  • Page 22

    D-3 MAINTENANCE D-3 1. Close the fuel shutoff valve located under the fuel tank. 2. Unscrew the cap ring located on the top of the filter header and remove the plastic center cap and O- ring. 3 . Remove the large white volume plug located directly under the center cap in the upper cavity of the filter header. Use a small screwdriver (or simi- lar d[...]

  • Page 23

    D-4 MAINTENANCE D-4 GFCI RECEPT ACLE TESTING AND RESET- TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage. • If the equipment has been shut down,[...]

  • Page 24

    E-1 TROUBLESHOOTING E-1 SAE-400 SEVERE DUTY If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION W ARNING ELECTRIC SHOCK can kill. • Do not touch electrically l[...]

  • Page 25

    E-2 TROUBLESHOOTING E-2 SAE-400 SEVERE DUTY Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

  • Page 26

    E-3 TROUBLESHOOTING E-3 SAE-400 SEVERE DUTY Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

  • Page 27

    E-4 TROUBLESHOOTING E-4 SAE-400 SEVERE DUTY Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

  • Page 28

    F-1 WIRING DIAGRAMS SAE-400 SEVERE DUTY F-1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.[...]

  • Page 29

    F-2 WIRING DIAGRAMS F-2 SAE-400 SEVERE DUTY NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.[...]

  • Page 30

    SAE-400 SEVERE DUTY F-3 DIMENSION PRINT F-3 M8869-36 A N.A.  .81 HOLES N.B.  .69 HOLES 28.00 22.00 22.14 24.50 27.12 6.00 39.69 47.95 23.00 26.00 38.50 63.06 50.13 21.00 44.00 8.90 44.50 69.75 8.12 77.00 3.00 81.25 .88 83.00 CENTER OF GRAVITY W ITH OIL AND W ATER IN ENGINE, BUT NO FUEL N.A. N.A. N.B. N.B.[...]

  • Page 31

    NOTES SAE-400 SEVERE DUTY[...]

  • Page 32

    W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA [...]

  • Page 33

    W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

  • Page 34

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]